Composite Resin Board Structure for Scratch Resistance and Recyclability
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Solution Overview
Problem
Existing thermosetting resins have complex production processes and are not recyclable, while thermoplastics lack scratch resistance, necessitating additional coatings that are less effective.
Innovation Solution
A board material combining a thermosetting resin with a thermoplastic resin, utilizing the thermosetting resin as a surface layer to enhance scratch resistance and allowing for recyclability by using a thermoplastic substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermosetting resin is used as the main material to achieve high scratch resistance, then the surface hardness and abrasion resistance are improved, but the production process becomes complex and the material loses recyclability
Solution Approach 1:
The board material is divided into two functional layers: a thermoplastic substrate layer that provides recyclability and processability, and a thermosetting resin surface layer that provides scratch resistance. This segmentation allows each layer to perform its specialized function while overcoming the limitations of using a single material for the entire board.
Solution Approach 2:
The invention uses a composite structure combining thermoplastic resin as the base material with thermosetting resin as the surface coating. This composite approach integrates the advantages of both material types: the thermoplastic provides ease of manufacturing and recyclability, while the thermosetting resin delivers superior surface hardness and abrasion resistance.
2Ease of manufacture
If thermoplastic resin is used as the main material to achieve good processability and recyclability, then the ease of manufacture and environmental friendliness are improved, but the surface scratch resistance deteriorates
Solution Approach 1:
Different parts of the board material have different properties: the bulk thermoplastic substrate maintains good processability and recyclability, while the surface thermosetting resin layer provides enhanced scratch resistance. This local differentiation of material properties allows the board to meet multiple requirements simultaneously.
Solution Approach 2:
The composite structure combines thermoplastic resin substrate with a thermosetting resin surface layer, allowing the bulk material to provide ease of manufacturing and recyclability while the surface layer compensates for the thermoplastic's insufficient scratch resistance.
3Strength
If UV coating is applied to thermoplastic surface to improve scratch resistance, then the surface protection is enhanced, but the scratch resistance remains far inferior to thermosetting resin and adds process complexity
Solution Approach 1:
The invention changes the fundamental parameter of the surface layer material from organic coatings (UV coating) to thermosetting resin. This parameter change transforms the surface layer into a material with inherently superior mechanical properties, including higher scratch resistance, while the hot-pressing process integrates this change into the existing manufacturing workflow.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The combination provides improved scratch resistance and enables recyclability, simplifying production processes and reducing waste, while maintaining cost-effectiveness.
Implementation Method 1
thermosetting resin has a high surface hardness after curing
Implementation Method 2
Upon being heated, they are easily formed by a calender or extruder, and after forming and cooling, they can be heated again for recovery and reuse
Implementation Method 3
the thermosetting protective layer comprising an abrasion-resistant powder
Data Source
Figure 1~2
AI summary
The present application discloses a board material comprising a thermosetting resin combined with a thermoplastic resin, which has any one of the following structures: (1) sequentially from bottom to top, a thermoplastic substrate layer, a thermoplastic pattern layer and a thermosetting protective layer, the thermosetting protective layer comprising an abrasion-resistant powder; or (2) sequentially from bottom to top, a thermoplastic substrate layer and a thermosetting full-body layer, the thermosetting full-body layer being obtained by distributing thermosetting resin materials of different colors, the thermosetting full-body layer comprising an abrasion-resistant powder, and the thermoplastic substrate layer having a single color or having a full-body texture.